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Cork bio-material robotic 3d printing

BIO ADDITIVE ROBOTIC MANUFACTURING

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YEAR2024

KINDGROUP

CATEGORYRESEARCH

FUNCTIONDESIGN PROTOTYPING, GRASSHOPPER, MANUFACTURING

This project investigates the integration of robotic 3D printing with sustainable biomaterials to create challenging and innovative architectural structures made with topological optimization.

ROBOTIC FABRICATION

With the pressing need to reduce carbon emissions in buildings by focusing on both operational and embodied energy, the project explored advanced additive manufacturing methods through robotic fabrication, aiming to improve resource efficiency and minimize waste. The use of robotic arms with multiple axes enhances 3D printing capabilities, allowing the creation of complex geometries and overcoming limitations of traditional layer-based printing, such as support for overhangs and material anisotropy thanks to non-planar prints.

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DESIGN & CODE

As a group engaged in this project, we are developed an architectural system using topological optimization, a method commonly used to optimize material distribution for structural efficiency. Through this approach, we merged computational design techniques with performance-oriented material application, resulting in structures that were light, stable, and resource-efficient. Our final designs, beign modular furniture pieces, were highlighted by their efficiency, stability, lightness, and design performance.

LAST

NEW MATERIALS AND NEW METHODS

In our project, we've focused on cork as a core material for creating biocomposites due to its unique properties and sustainability. Cork is not only 100% natural, reusable, and recyclable, but it also stands out for its resistance to fire, high temperatures, friction, and its impressive ability to provide thermal and acoustic insulation. Additionally, it’s hypoallergenic, impermeable to liquids and gases, and has great elasticity and compressibility.

We combined cork granules with binders such as xanthan gum and gelatin, along with additives like bicarbonate, to create a versatile biocomposite. The mix allowed us to print the cork into different forms while maintaining its lightweight and durable characteristics. Through proper mixing techniques and proportions, we were able to achieve a homogenous, viscous mixture suitable for experimental applications with the robot.

The process followed in the workshop sees cork not only as a sustainable resource but also as a material that can perform well under practical conditions, with tests showing impressive resistance to pressure. The project's mix formulations and material testing reflect how cork-based biocomposites could be used in various design and architectural applications, reinforcing its potential beyond just being a natural material—pushing it toward more advanced, performance-driven uses.

ROBOT MANUFACTURING: NEW WAYS OF MAKING

Reflecting on our project, we’ve come to appreciate just how impactful robotics can be in architectural fabrication. Working hands-on with robotic kinematics, simulations, and control systems gave us a much clearer picture of how to connect design and actual construction through a "file-to-factory" approach. What really stood out during this process was the precision and flexibility that robots bring to manufacturing. Tasks that would be difficult or impractical by hand or other traditional manufacturing methods became achievable, and with consistent, high-quality results.

The ability to attach different tools to robots also adds a huge layer of versatility. It feels like we were no longer constrained by traditional fabrication limits, opening up new design possibilities. Plus, in our case, using robots with biomaterials really highlighted the potential for more sustainable and efficient building methods.

In the end, this project reinforced how robotic manufacturing can not only make fabrication smarter and more efficient but also help us think about creating environmentally responsible solutions. It’s helped us see the future of design in a whole new light, both technically and sustainably.

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